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Abstract—Extensive competition in manufacturing have left no space for system inefficiencies and it
has evolved a manufacturing environment which seeks reduced manufacturing lead times, increased
quality standards, vast product variety and competitive cost. The trend towards globalization requires
these manufacturing environments to be designed such that it can cater challenges of market place to
survive and grow. To cope with these challenges the technologies support with automation and
flexibility. The objectives of improvement of manufacturing environment are the basis of emergence of
flexible manufacturing systems (FMSs). In this paper a case study of small and medium enterprise
(SME) is presented with contribution of some performance improvement methods for flexible
manufacturing system. Analytical models illustrated in literature are employed to estimate the
performance measures like utilization and maximum production rate. Development of an improved
design for existing flexible manufacturing system of SME is also part of this study. In addition to
simulation of manufacturing system, various performance parameters are compared and evaluated for
existing and improved FMS.
Keywords— Flexible Manufacturing System, Utilization, Production Rate, Performance Measures
1. Introduction
Intense competition in manufacturing environment offers new strains to the manufacturing systems,
such as increasing diversity, delivery on time with emphasize on conventional standards of quality and
competitive cost. Therefore, in global scenario, the focus is on a developing manufacturing system that
can meet all the required conditions within due dates at a reasonable cost. The introduction of flexible
manufacturing system (FMS) allows manufacturing industry, to improve their performance, together
with the flexibility to make individual product at medium volume. A flexible Manufacturing system
(FMS) can be defined as a computer-controlled configuration of semi-dependent jobs and material
handling systems designed to efficiently produce different mixes of product with low to medium
volume. It blends high flexibility with high productivity and low work-in-process. The delicacy of the
FMS is that it is taken from the ideas both from the current loading and batch workshop manufacturing
system and is designed to imitate the flexibility of job shops, while maintaining the effectiveness of its
own. To meet demands with minimum marksman simultaneously is should be objective a
manufacturing system such as FMS. A general FMS is able to process a variety of products in small
and medium batches simultaneously. The Flexibility of a flexible manufacturing system (FMS)
enabled it as the most appropriate manufacturing systems in the current manufacturing circumstances.
With the aim of producing combining flexibility and productivity, the design of the Flexible
Manufacturing System (FMS) is the subject of huge investment. Deterministic Models are based on
discrete event simulation, can be used to design the production Systems such as FMS. The distinctive
design and size of the hardware requirements for an FMS require attention and care at strategic level.
The layout and design of the system is to be designed by keeping the targeted production in mind
ensuring that FMS will fulfill the fluctuating demands. The design decisions must be based on the
FMS to justify the performance improvements. This paper presents the evaluation of existing flexible
manufacturing system with the objective of improvements in the performance of system by bringing
modifications into the system.
2. Literature Review
The concept of providing variety of products with flexible manufacturing processes in large quantities
at the lowest possible cost incurred in the late 1980s.The flexible manufacturing, after decades of
Two main factors which are drivers of the necessity of manufacturing flexibility are identified as
In the first case, flexibility confronts unexpected situations both from inside the system and outside the
system whereas in second case, flexibility is supposed to offer variety of products in order to keep up
manufacturing processes. Changes within the manufacturing system are considered inconveniencies
like machine failure, variability in work time and unavailability of raw material (Buzacott 1989)
Machine flexibility and routine flexibility are more specific categories of flexible manufacturing (Peter
Kostal, Karol Velisek 2011). Machine flexibility deals in manufacturing of different products with a
given machine and routine flexibility addresses the execution of the same operation by a range of
machines. This study will stick with these categories of manufacturing flexibility. The need of
flexibility is emerged from factors such as uncertainty of demand, shorter product and technology life
cycles, shorter delivery times, increased product variety and increased customization (Toni, Tonchia
1998). The flexibility offered by FMS has limits such as its development is based on fixed amount of
information and absence of learning process (Schonberger 1986). Thus, to address highly uncertain
demand and manufacturing of very wide variety of products, more responsive system is required so
from here shift from flexible to agile manufacturing takes place.
The understudy enterprise is situated in the capital territory of Pakistan. It is leading manufacturer of
CNG equipment electrical control devices from last fifteen years. Domestic and industrial appliances
are included in the broad list of Tesla Technologies. Electric element, Electric thermostat, heater safety
devices, hoses, gas geysers, Hydraulic compressed natural gas compressor and LPG dispensers are
among the products of the understudy enterprise. The products of the enterprise are spread over the
markets of thirty cities of Pakistan and from last eight years the enterprise has entered into the global
market and expanding its exports at fast pace.
The exported products of the enterprise are certified by the British Electro-Technical Approvals Board
and British Gas. Various ISO certifications are also part of the credentials of the Case enterprise (Tesla
Technologies). The Electric Element shortly known as “EE” is one of the products of the enterprise
whose manufacturing and assembly process is focused in this study.
The process of making electric element starts from tube cutting. The tubes are cut in various lengths as
per demand by the customers. A semi automatic machine is employed to cut the hollow tubes. The lot
of cut tubes is transferred to the head closing lathe where one side of the hollow tube is closed. The
In parallel to the tube cutting station the spring making station is working. The springs are made using
CNC machine. Spring holding pins are inserted in both sides of the spring and then welded by spot
welding machine. The whole lot of springs is transferred to Mgo filling station where the springs are
inserted in tubes. After inserting the springs in tubes individually, Mgo is filled in tubes. Mgo filled
tubes are sent to the testing station where weight and continuity of each element is tested. The
elements with less than standard weight are refilled with Mgo manually. After these test the elements
are transferred to the reducing machine where diameter of the element is reduced gradually. The
reduced element is now sent to marking station, where elements are marked for upcoming annealing
process. The marked elements are annealed at very high temperature for few seconds, after annealing
the elements are sent to bending machine where they are bent according to desired shape. The
elements after bending are sent to the dryer for drying. The elements after drying process are sent to
base assembly station. The elements are attached with bases and tube in which thermostat is to be
inserted is also attached with base. From now, the semi finished, elements are sent to brazing station
where each element is brazed individually. The brazing is followed by a crucial pressure test for
leakage testing. The failed elements are brazed again and the elements which pass the test are
transferred to the epoxy filling station where epoxy is filled in every individual element. Epoxy filled
elements are sent to first micro line test where electric parameters are checked thoroughly. The
elements are now transferred for wire holder attachments. At this station the wire holder is attached to
the main element. Cleaning is done at the station and the elements are sent to next station where
thermostats are inserted in one tube of elements. After thermostat insertion the elements are sent to last
micro line test where elements are tested in detail. The failed elements are placed for drying and
rechecked after a delay. The passed elements are sent to packaging station where they are packed and
stored in finished goods store. It is to be mentioned that each type of product follows the same
processing sequence.
The case SME is producing four different types of electric elements. The SME is cycle of continuous
growth and frequently goes for expansions. Currently the SME is facing the problems of unmeet
demands due to imbalance of resources and very less utilization. Analysis of existing system leads to
various improvement strategies. The production process and processing times along with the product
mix is presented in Table 1.
Various models are demonstrated in literature to probe into a manufacturing system. Physical models,
simulation model and analytical models are most extensively used for study and development of
manufacturing systems. Manufacturing systems are so big arrangements that they cannot be physically
modeled and experimented. So, physical models are not fit for manufacturing system investigation and
improvement. Simulation modeling is partially used in this study. Simulation study involves
uncertainties and requires statistical verification at the end. Analytical models offer most certain results
and used in this study as primary source of system analysis and improvement. To carry out modeling
of manufacturing system various assumptions are need to be established.
The study is carried out at process level i.e. operational level. Various operational parameters
investigated are presented in following lines.
To estimate different performance measure of system the workloads on each workstation is required to
be calculated. The workload on each station is precisely defined as the average time spent on any
station by the product or item. Further, the workload will help to define bottleneck station(s) of the
system.
Equation 1
In above equation
= Average workload for station (Minutes)
= Processing time for operation in process plan at station (Minutes)
= operation frequency in operation part at station
= Part mix for part j
The average workload estimated for different workstations of existing system is presented in table 2
Equation 2
The workstation which has largest workload to number of servers ratio is a bottleneck station. The
microline testing station concluded as bottleneck station. Workload to server ratios of all workstation
is summarized is presented in table 3.
The maximum production rate is controlled by the station which is concluded as a bottleneck station.
To have maximum production rate of the parts the ratio of number of bottleneck station severs to the
workload of bottleneck station is required to be calculated. This ratio will define the maximum
production rate of the existing system.
Equation 3
By implementation of above formula the maximum production rate for existing system is 112.5 Pc. /hr.
1125 Pc. /day (10 Hours a day). The individual production rate of any manufacturing station can be
estimated by applying equation 4.
Equation 4
The amount of time a specific workstation is working and not in idle condition is defined as mean
utilization. Utilization of each workstation can be calculated by using equation 5. The bottleneck
station has always 100 % utilization.
Equation 5
Table 4 presents the utilization of each workstation of the existing manufacturing system.
Equation 6
By using equation 6 the overall utilization of system can be calculated. The utilization of existing
system is 36 %.
5. Conclusion
The study was to analyze the existing system and to improve performance of the system by
reconfiguration of flexible manufacturing system. Various techniques such as analytical modeling and
simulation modeling were used to achieve the objectives. First, various performance and operational
parameters were estimated then new FMS has been proposed with the optimum number of servers. The
findings explored that microline station was being utilized at 100 %. These results indicated that the
microline testing station is a bottleneck station. Since this station is crucial for the processing all sub-
types, it is proposed that the bottleneck is to be moved from this station to some other less important in
the proposed FMS. Utilization was found another core issue in the understudy system. It is concluded
that the resources of the system were underutilized severely. 11 servers were added into proposed
configuration that is about 36 % percent increment was made. The utilization was increased from 35%
to 76% that is about 110% increase in utilization was made by merely 36 % increase in number of
servers. As a result of modification and sizing the FMS the throughput of the system was increased
from 107 pc per hour to 316 pc per hour. For future study in the SME the layout and material handling
system can also be investigated with a hope of further improvement in the system performance.